GYS MIG, T Series Welder Instruction Manual

GYS MIG, T Series Welder

Product Usage Instructions

• Installation:
  • Follow the torch connection requirements as indicated in the manual for each respective model.
• Safety Precautions:
  • Wear appropriate protective clothing.
  • Avoid contact with hot surfaces during and after welding.
  • Ensure proper ventilation in the workspace to avoid inhaling harmful fumes.
  • Disconnect the power supply before performing any maintenance.
• Welding Process:
  • Prepare the workpiece and ensure it is clean and free of contaminants.
  • Select the appropriate welding parameters based on the material and thickness.
  • Securely attach the workpiece and ground clamp.
  • Start the welding process while maintaining a steady hand movement.
  • Monitor the welding arc and adjust settings as needed for optimal results.

FAQs

• Q: What gas should be used with the MIG/MAG welding mode?
  • A: The recommended gases are CO2 or mixtures specified in the manual for each model.
• Q: How do I ensure a proper torch connection?
  • A: Refer to the detailed torch connection diagrams provided in the manual for each torch type.
• Q: What safety precautions should be taken while using the welding machine?
  • A: Wear appropriate protective clothing, ensure proper ventilation, and disconnect the power supply before maintenance.

WARNING SAFETY RULES

GENERAL INSTRUCTIONS

• Read and understand the following safety instructions before use.
• Any modification or updates that are not specified in the instructions manual should not be undertaken.
• The manufacturer is not liable for any injury or damage due to non-compliance with the instructions featured in this manual.
• If there is any issue or uncertainty, please consult a qualified person to handle the installation correctly.

INDIVIDUAL PROTECTION & OTHERS

Arc welding can be dangerous and can cause serious injury or even death. Welding exposes the user to dangerous heat, arc rays, electromagnetic fields, the risk of electric shock, noise, and gas fumes. People wearing pacemakers are advised to consult a doctor before using the welding machine. To protect oneself as well as others, ensure the following safety precautions are taken:

• To protect you from burns and radiation, wear clothing without turn-ups or cuffs. These clothes must be insulating, dry, fireproof, in good condition, and cover the whole body.
• Wear protective gloves that guarantee electrical and thermal insulation.
• Use sufficient welding protective gear for the whole body: hood, gloves, jacket, trousers… (varies depending on the application/operation). Protect the eyes during cleaning operations. Contact lenses are prohibited during use. It may be necessary to install fireproof welding curtains to protect the area against arc rays, weld spatter, and sparks. Inform the people around the working area to never look at the arc or the molten metal, and to wear protective clothes.
• Ensure ear protection is worn by the operator if the work exceeds the authorized noise limit (the same applies to any person in the welding area). Keep hands, hair, and clothes away from moving parts such as fans, and engines. Never remove the safety covers from the cooling unit when the machine is plugged in. The manufacturer is not liable for any injury or damage caused due to non-compliance with the safety precautions.
• Parts that have just been welded will be hot and may cause burns when touched. During maintenance work on the torch or the electrode holder, you should make sure it’s cold enough and wait at least 10 minutes before any intervention. When using a water-cooled torch, make sure that the cooling unit is switched on to avoid any burns that could potentially be caused by the liquid. It is important to secure the working area before leaving it to ensure the protection of the goods and the safety of people.

WELDING FUMES AND GASES

• The fumes, gas, and dust generated by cutting are a potential health hazard. You must ensure adequate ventilation through the installation of air supplies to extract fumes and gases.
• Using an air-fed welding helmet is recommended in case of insufficient ventilation in the workplace.
• Check that the air supply is effective by referring to the recommended safety regulations.
• Caution, welding in small spaces requires surveillance from a safe distance. Welding certain pieces of metal containing lead, cadmium, zinc, mercury or beryllium can be extremely toxic. The user will also need to degrease the workpiece before welding.
• Gas cylinders must be stored in an open or ventilated area. They must be stored vertically and held by a support or trolley to limit the risk of falls. Do not weld in areas where grease or paint are stored.

FIRE AND EXPLOSION RISKS

• Protect the entire welding area. Flammable materials must be moved to a minimum safe distance of 11 meters.
• A fire extinguisher must be readily available near the welding operations.
• Be careful of weld spatter and sparks, even through cracks. If not careful then this could potentially lead to a fire or an explosion.
• Keep people, flammable materials/objects, and containers that are under pressure at a safe distance.
• Welding in closed containers or pipes should be avoided and, if they are opened, they must be emptied of any flammable or explosive material (oil, fuel, gas …).
• Grinding operations should not be carried out close to the power supply or any flammable materials.

ELECTRICAL SAFETY

• An electric shock could cause serious injuries or potentially even deadly accidents. Do not touch any live part of the machine (inside or outside) when it is plugged in because they are connected to the welding circuit.
• Do not touch the torch or the earth clamp at the same time.
• Always wear dry clothes that are in good condition to be isolated from the welding circuit. Always wear insulated shoes, regardless of the environment in which you work.

PRECAUTION FOR USE

• Never wrap the welding leads around your body.
• Do not use the torch to move the welding power source or wire feeder.
• The torch must be fully uncoiled to prevent overheating.
• Switch off the generator after the torch is cooled before each maintenance and before replacing or control wearing parts.
• Regularly check the condition of the torch. If damaged, the torch must be replaced.

GENERAL DESCRIPTION

SPECIFICATIONS

• The MIG 15 / MIG 25 / MIG 36 / TT120 / PT120 torches are intended for the manual MIG / MAG welding processes.

TECHNICAL SPECIFICATIONS

Part number| Component| 072121| 063754

082151

| 063761| Component| 063778| 063785| 063792| 063808| Component
---|---|---|---|---|---|---|---|---|---|---
71846| 71847

063754

| 71848

072138

| 71866

072145

| 71879

072152

| C71453| C71454| 53277| C71391| 71392
Name| MIG 15| MIG 25| MIG 36| TT120| PT120
Process| MIG / MAG| MIG / MAG| MIG / MAG| NO GAS MIG| MIG/MAG
Guidance method| Manual| Manual| Manual| Manual| Manual
Rated current Corresponding duty cycle| 150 A

35%

| 180 A

60%

| 230 A

60%

| 340 A

60%

| 120 A

35%

| 120 A

35%

Rated voltage| ≤113 V| ≤113 V| ≤113 V| ≤113 V| ≤113 V
Cooling mode| Air| Air| Air| Air| Air
Connections| EURO| EURO| EURO| Fixed| Fixed
Gas protection| 150 A CO2 /

120 A Mix

| 180 A CO2 /

150 A Mix

| 230 A CO2 /

200 A Mix

| 340 A CO2 /

300 A Mix

| ****

–

| 120 A CO2 /

100 A Mix

Gas flow| 10-18 L/min

(2.64/4.75 US

gpm)

| 10-25 L/min

(2.64/6.60 US gpm)

| 10-25 L/min

(2.64/6.60 US gpm)

| 10-25 L/min

(2.64/6.60 US

gpm)

| ****

–

| 6-15 L/min

(1.58/3.96 US

gpm)

Contact tube| Ø 0.8

Steel

| Ø 1.0

Steel

| Ø 1.0

Steel

| Ø 0.8

Steel

| Ø 0.8

Alu

| Ø 1.2

Alu

| Ø 0.8

Steel

| Ø 1.0

Steel

| Ø 1.0

Steel

| Ø 1.0

Steel

| Ø 1.0

Alu

| Ø 1.2

Steel

| Ø 1.2

Alu

| Ø 0.9

Steel

| Ø 0.8

Steel

Cable length| 3m| 3m| 3m| 3m| 4m| 4m| 3m| 4m| 3m| 2.5m| 2.35m| 2.2 m| 2.4m
Cross section| 14 mm²| 16 mm²| 25 mm²| 42 mm²| 10 mm²| 10 mm²
Switch trigger voltage| 10 V| 10 V| 10 V| 10 V| 10 V
Functionning temperature| – 10 → +40°C
Storage temperature| – 10 → +55°C
Applied standard| IEC 60974-7

SET UP

TORCH CONNECTION REQUIREMENT

• MIG 15-25-36
  • The generator must be switched off.
  • Insert the torch connector (A) in the female connector (E) and screw the part B. Make sure the torch is tight enough.
  • To remove the torch, unscrew it as shown below.

TT120 – TP120

The generator must be switched off.

1. Open the cover.
2. Unscrew the 4 screws (framed in black).
3. Disconnect the cables and remove the torch.
4. Replace the new lamp.
5. Reconnect in the same way and then screw it back on.

TORCHES EQUIPMENT

• The torch must be fitted with the appropriate consumables, selected based on the application and selected current.
• Using the wrong consumables will result in poor cutting, excessive use of consumables, and possibly prevent the machine from working.

Welding Spatter:

• When welding, the spatter can easily damage the torch and welding equipment. To avoid constraints on the wire feeder, decrease arc stability, or reduce the gas isolation effect, spatter and other depot build-up in the nozzles must be cleaned as soon as necessary.
• Accumulated spatter in the nozzle will cause a short-circuit which could damage the torch over time if not cleaned in due course.
• The use of an antisplatter spray or paste is recommended. To avoid damage to the torch, do not use a cutting tool to clean it.

Torch MIG 15:

Torch MIG 25:

Torch MIG 36:

Torch TT120

Torch PT120

Consumables

Regularly check the wear condition of the contact tube 3 and the nozzle 4.

Ø 0.6/0.8 mm

| 3 m| 041592| 041578| –| –| –| –
4 m| 041837| 044050| –| –| –| –

Ø 1.0/1.2 mm

| 3 m| –| –| 041608| 041585| 041608| 041585
4 m| –| –| 041844| 044067| 041844| 044067
5 m| –| –| 062276| –| 062276| –
8 m| –| –| –| 038677| –| 038677

2

| Contact tube support|

MIG 15

|

MIG 25

|

MIG 36

---|---|---|---|---

150 A

| A1 x 5| 042902| –| –
A2 x 10| 042988| –| –

250 A

| B1 x 5| –| 042995| –
B2 x 5| –| 042919| –

350 A

| D1 x 3| –| –| 043008
D2 x 5| –| –| 042926
3  Contact tube| MIG 15| MIG 25| MIG 36| TT120 / PT120
---|---|---|---|---
Ø 0.6| x 10| 041905| –| –| 041905
Ø 0.8| x 10| 041912| —| –| 041912
Ø 1.0| x 10| 041929| 041066| 419803| 041929
Ø 1.2| x 10| 041974| 041073| 419810| 041974
4 Nozzle| MIG 15| MIG 25| MIG 36| TT120 / PT120
---|---|---|---|---
150 A| 041875| –| –| 041875
250 A| –| 041882| –| –
350 A| –| –| 041783| –

TROUBLESHOOTING

TROUBLESHOOTING, CAUSES, SOLUTIONS

Check and tighten the contact tube and its support.
Excessive welding current.| Adjust the current on the machine.
Inoperative trigger| The wire control is cutted or damaged.| Repair the wire
The euro connector of the torch is not connected correctly to the machine.| Check the connection of the torch.
Wire welded in contact tube| Incorrect settings Contact tube used.| Check or correct the setting. Change the contact tube.
Irregular wire feed| Roller pressure is too low or too high| Change roller pressure (on the feed motor)
The feed sheathing is clogged.| Clean both ends
Contact tip incompatible with the wire diameter.| Change the contact tip.
The wire feeder roller is worn out or incorrectly fitted.| Change the wire feeder roller.
The wire feed not working correctly.| Check/repair the reel

The arc between the nozzle and the part to weld

| Short circuit between the contact tip and the nozzle due to spatter.| Clean the nozzle and spray the anti-spatter agent inside.
Damaged isolator contact tip.| Change the nozzle.
Unstable arc| Worn-out contact tip or inadequate contact tip with the diameter of the wire.| Check and change the contact tip.
Incorrect setting of the welding machine.| Correct the setting of the welding machine.
Internal sheath wire deteriorated.| Change the wire liner in the torch.

WARRANTY

The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labour).

The warranty does not cover:

• Transit damage.
• Normal wear of parts (eg. : cables, clamps, etc..).
• Damages due to misuse (power supply error, dropping of equipment, disassembling).
• Environment-related failures (pollution, rust, dust).
• In case of failure, return the unit to your distributor together with:
• The proof of purchase (receipt etc …)
• A description of the fault reported.

SYMBOLS

• The devicecomplies with European directives, The EU declaration of conformity is available on our website (see cover page).
• Equipment in compliance with British requirements. The British Declaration of Conformity is available on our website (see home page).
• Equipment in conformity with Moroccan standards. The declaration Cم) CMIM) of conformity is available on our website (see cover page).
• This product should be recycled appropriately D
• This hardware is subject to waste collection according to the European directives 2012/19/EU. Do not throw out in a domestic bin!

CONTACT

• SAS GUYS
• 1, rue de la Croix des Landes
• CS 54159
• 53941 SAINT-BERTHEVIN Cedex
• France
• Find more languages of user manuals on our website
• www.gys.fr.
• MIG 15 / MIG 25 / MIG 36 / TT120 / PT120

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